1974 FORD CAPRI clutch

bluetooth hood open ignition suspension cabin filter service indicator

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FORD CAPRI 1974 Workshop Manual ) Chapter 6 Manual gearbox and automatic transmissio n
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1 5. 17 MC~Sll"nu corchp· 10·SPCI1(lOIllClcr drivcgc,l dImension 1 5 .1 8 Sc lcCl0f Sholl! t1sscmlJ lcct 1521 FIlling s

) Chapter 6 Manual gearbox and automatic transmissio n
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1 5. 17 MC~Sll"nu corchp· 10·SPCI1(lOIllClcr drivcgc,l' dImension 1 5 .1 8 Sc lcCl0f Sholl! t1sscmlJ lcct 1521 FIlling selector sh1lft/boss fall pin
15.23 Speedome ter dJlvcgcn, cove.
IOCkmg cOI1l,ol hy Inserl;"y the 1)111 ;lnd 1>lu9 2 1 Ahgn the holes. then (lillie Ihe roll pin il1lo the sc lcCIOf boss ;111\1 SI~ICC1Of s h _ 3 Fit Ihc SPCCdOIllCICI dnV(!IJciII to tho r(!J' ex tenS Ion housing. Apply " ionic scali.., 1 10 Ihe cove. Ihe'l pro ss II 111\0 \he housinU (phOI0) . . nornavc the 1 (!U1llOHUl1y flHed bolts 1'001 Ihe mlCfllIcd.nle housing. •.• en scle<:1 4th {Jom. 25 Slick n new \Jaskot 10 the e~tcnSlO" housing with glC,1se. ,md fot the hOusing 10 Ihe inle,mcd'Jle housi"g T .. ke c", e nOI to (I,ml all seal. ,1"d m,1ke sUle th 26 Insert the bolt s .:md tighten them to thespcclflod to'Que In d,agon .. 1 sequence. Befo.e Inserting the Ih.ee bolts which go light through tllo
main c .. sing ... pply se se leclor rod . Support the rod wi th a piece of wood. then drive in the '011 pin_ Selec t neutral. 28 Press the .eil' cover into the extension housing .
29 Check that the 5th gea. interlock slceve is corrcctly .11ognoo. then 'nscrt thc Sth geil' locking pin and spring.
30 Appl y some scalallt to the 5th geilr locking plate. 10Cilte It on thO extensio n housing. an d inselt nnd t igh ten th e bolts to I h e specIfIed torque. 31 Fit the Ueilrbo~ top covcr. together WIth a new gas\(et. and lighten
the boilS to t he sf1eclf.ed tOfQue in diagonal sequence. 32 F u the clulC h relCilSe bearing guide sleeve (oil slot dow nwllfd s). together with a new gilsket. and lighlen th o boi lS to the specillt~d torque in d;ilgon;11 sequence. Where neceSS;1ry apply seal,.nt to the bolt threads_ 33 Fitthe clutch bell housing to the Iron t 0: the gearhox. together woth new gaske t. Apply sealant to the bolt threads. thcn inse n the boilS .~d tigh ten them to Ihe SIXlcllled 10rQue in diagonal sequence. 34 Inscrt and trgh le n the .ev(usinl.l Ioght switch in Ihe ex tensio n housing
1525 Selec tor sh aft spring pin (arrowed)
35 FIt the clutch reLease l"l'lIIng and a.1Il wuh .efercnce 10 Chnl)\ el 5.
16 G e(lr box (5-spee{l) -d isellg i:lgem enl of 5th gear
I I
is possI ble 'or vducles hu,l t bclo.e NovcmiJer 1983 to have i:l p.oblem WIth 5th ne". Illillplllg Ollt of cnuanClllcn t during normal
(hlv lnu
2 ThiS 1I0uhle Cilll he rcc tl',cd hy suhstitutinu nlod,hc componen1S t o Inc lude thO hub. o!\Ulk ""gs .. nd sci(.-ctor 'ork.
3 Rem ove Ihe gearbo_ "s de$("bed in SectIon 3. This wrll nCCCSSlla te lemov ing the ge(l' Icvcr "nd lu"C I cove. whIch is held In ,)OSltlo n by TOOK typc sClews . 4 Removo the clutch Hlleilse bearing and tevcl 110m the bclthousing . 5 Unbolt ami lemovc the lOP covel. 6 C"ory out the opel,1t'0"S dcsc llbed in par "graphs 8 10 1" 01 Seclion
" 7 M"r\( Ihe ex.1Ct IIOS""o n of t he speedometcl wormdrive on the milinshil lt (lnd then draw it off using a pulter .
8 Extr"ct the ci. et,p "nd H)move the 5 th sp(lcd sync hro unil/rom Ihe
mJinsh"lt. 9 Dismanlle the synr.hro "nd reasscmble using the new p" rts, When I Itting t he b"ulk lings. m"ko sure that theil bevelle( 1 side is tOwa.ds the
re,,' o f Iho ge",box. 10 Caffy out the ope,,,,,ons desCfibed in jh"lfilgraphs 16 to 22 and 25 1027 in Section 15. 11 Inser t the 5 th ge 1 0 the light whIle "1 tho} neul'il' mode and then tighten the locking plate nutS to ill o 'que 0125 NIIl (l8tbl It). 14 Fit the top cove. olnd gasket and I he clu tc h release components.
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FORD CAPRI 1974 Workshop Manual , 22 Chapter 6 Manual gearbox and automatic tran smissio n
17 Fllult dingllosis -IlH IIlU<l I gCMboll
Symptom
Weak or in effec tive synch romesh
Jumps out of gem
Excessive noise
Exces~ivo diff

, 22 Chapter 6 Manual gearbox and automatic tran smissio n
17 Fllult dingllosis -IlH IIlU Symptom
Weak or in effec tive synch romesh
Jumps out of gem
Excessive noise
Exces~ivo difficliity III enonU ing (]0,11
P ART 2: AUTOMATIC TRANSMISS IO N
18 Gen eral description
Thc aulOma llC l,an~nHss'on ,;rkl:~ lhe JlI"Ct~ uf the clutch and Hcmhox. wh,ch ,"c. of cow se . mounte(1 heh,nd lhe enu;ne . The unil has a 1"'{lO nluminl"'" content which helps to .elluc" liS
overall weinhl and 11 IS o f compact dimenSions. All 0,1 coole. 's filled ,IS
Reilson (s )
Sy nchronising cones worn, spilt Of dmnaU ed O~ulk rin g sy nch romes h dogs worn, or dmnagcr!
Broken gcarc h,lnUC fOfk rod spring Selector fo rk rod !IIOOye h.ldly worn
Inen!!cc! 9(,1(10 of oil in gc,llhox 0' 0,1 level 100 low Bu sh or ncc(tie roller hC GeM welh exce ssively WOrtl 0' (l;Ullll!Jcd
l;'lync:u 1hru st W;'\ShCfS w or n ililowing excessive cndplilV (folll,spC C lu tc h cilhle .1(tjllsllllcnl in corrcr. l
Sliln da.d .. nd ensules cooler OI)(lI.lI1Qn of the \.,lnSUlISSlon lind!)! l.a>l." lowinU ;lnd sunlla. conrll1i0l15 . A VaClIl,Hll conncctlon 10 lhe IIII~I manifold p,ovldes smoO lh cr anrl morc conSI$1r.1l1 clownstlll,S IIndc. load than IS the case Wilh IIn,lS nOl !IlcOlI)Or.11U1IJ lh,s f,,(:Illly The sysle m cotlllJltses lWO tIl.lin com(lonenrs.
(.1) A /"ree e/c'mcnl "v,/lokinc/ic IOUIIIII I:Ollvcrler cOII/,lmy 1:;'I'.1h1(.' o f /orqu c 1II1I!lIplicii /iorr ;, 1 .1/1 irr"mldv Villl;,hle r.1/1O (h) A /unluC/Sln'cd respOlIsiv~ .md IWdwlllrI:illlv IIIIL'f.1lCr! cp'· qL"fie f/c.1rbox COIIII}liSIilf/ pl.wel.l/V m:.lISII/S /IIovidmy tlllf:C forw.l/d 1.1/ios "llff OIlC Icvcrsc ril/'O
Fig . 6.24 C utllw ay view of th e a utomatic transmission (Sec 18)
1 GovelllUi ,'ssemblv 6 rop/leve/sc clu/e h 10 FlOn/ SCIVO 2 GOVlIIJI OI IIlIb 7 FIOIII blilkc bil/Jd /I Valve botlV 3 Olle ·w/lV cfalclt 8 rorquc convenor 1 2 V/lcuum diaplu/lym 4 IlCill bfiJ~C baml 9 Hvdraufic pump 1 J Re/ll servo 6 Forwlllfl cia/eli
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FORD CAPRI 1974 Workshop Manual Chapter 8 Rear axle 141
lings apm! and compress the clutch plntes. The nction is varinble. depending on the power npplied. so tlMt under full power the dIfferential will lock completely nlld full to

Page 200 of 205

FORD CAPRI 1974 Workshop Manual )
rernoy .. and refl Uing -69 spcc,iC<ltions -66 Carpets maimcnancc -1 76 Centre console removal .. nd refluing -189 Choke . au tomatic _ 71 Cigar ighter romoval ;lIld . e ru in g -225 C loc

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rernoy .. ' and refl Uing -69 spcc,'iC d'ilUlinU 59
(IlIvchells
G3 e~p:mSloll I nnk 6<1 Ian hub l)()nllllH (30 hilI] 1110<1111,;) 64 f~ull (II;)Ul1osl~ 65
flll".U -
60 lIush"'9 59
",nmlen,lncc. roullllC 59
'ild,nlOr
GO speclficn llon5 57 lem,)er;!lurc unuuc Sf:n(Ie. unil -134 IhcrmOSl<11 -61 10Htlle wrench selll ngs 57 VISCOUS drlv\! 11'111 -63 W1)ler IWIllP 61 Crankca se ventiln tion system 2.8 tol'c engine -39 3.0 rillC engine 53 Cranksh1)ft 2.8 li l.e engine examinat ion nnd rcnoviuion -37 refilling -<10
3 .0 til.e cn gine examination lind renOV1'l110n -52 Crankshilft and main bearings (3.0 litr o engino) removal -51 Crankshllft pulley refitting (2.8 hIre engine) -44
removal ( 3 .0 litre engine) -50 Crankshaft r ear oil seal (3.0 litre engine) .efllling - 55 .emova l -51 Cylinder bores ~xaminalion and .enovation -36. 51 Indo r heads 2.8 titre engine dismanll ing .• cnova lion and .eassembl y -35
Index
D
refining - 45
3.0 litre engin e
. eassembly -55 refining -55 .emoval wilh engIne -49
removal wil h engine in car -49
Decarhonising -52 Dimensions. vehicle _ 6 Dim-dip lighting system _ 226 Disc br1lke s scc Front disc brakes Distributor overhaul 2.8 hlle engIne -93 3 a !r1l0 cng,ne -92 rcmoval and r efIlling _ 90 Doors eXle.io. hllndle ,emoval and refilling - 183 lock 1Issernbly removal and .efilling -184 pillar swi lc h -224
priVill e lock ,ernovill and ref'lIing -185 fnllics tracing nnd feCllik al ion -178 remOle conlroi hnndle removal and refilling -180 Hlmoval and rell\1l11g _ 185 Irim j>ilnel removal and ,efi ning _ 182 window Irnm c
moul(II ng nnd door wealhcrSlrips
removal and refining -185 rcmoval and relining -185 wmdow glass removal and retilling - 184 window regulnlor nssembly
r emoval and relilling -183 Drivebelt s .emov,,1 ilnd refil ling -63 Drum brakes sce Renl drum brakes
E
Eloc triclIl.system -198 e/ seq Electrical systcm altell11110, -201 10 203
ilu xiha.y driving "ghl -212 bmlery -200. 201 bulbs -199.21310217 ciga. IighlOf -225
clock -223
d escrip llon -200 dim-dip ligh ling syslem -226 laull diilgnOSIS -19. 233 ""sher unils and rel1lys -225
fuse s -199. 220
headligllls -211 10213 horn -220
inSI.ument clUSler -22 1 inSI.ument vollage .egula lor - 226 Inmp5 -21410217 mninlenance. fOUline w 200 mobite r"dio equIpment - 226
precautions - 200
rildio /casse tte player -226 specif ications - 198
speedomeler cab le -226 Slmte . mOlOr -207 swi tches -223 10 22 5 lailgall) wash er -217 laHgme wipef -217 to.que wrench sell ings -199
w indscree n washer -219 windscreen wiper -21810 220 wi.ing diagrams -235 10 249
25'
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FORD CAPRI 1974 Workshop Manual " .... Index
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Engine -23 cl $cq Engine (2 .8 litro) lmcillllries -29. 36 camshaft -35, 41 components e~aminlltion for wear -34 connecting rods -37. 42

" .... Index
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Engine -23 cl $cq Engine (2 .8 litro) lmcillllries -29. 36 camshaft -35, 41 components e~aminlltion for wear -34 connecting rods -37. 42 crankcase ventilation system -39 crankshllft -37, 40 crankshaft pulley -44 cylinder bores -36 cylinder heads -35. 45 description -26 dismantling -29 fault dingnOSlS -20. 56 flywheel -38. 42 front interm!.lt hate plme -41 gudgeon pins -37 lubriClllion system·-39 main Il!ld big·end bellrings -37 rll(lintenance, routine -26 OIl pump -38. 42 operations possible with eng :ne in car -22 op(!r;lIions rC'quiring engine remov,,' -22 iSlOn rings -36 pistons -36. 42 rC(lssembly -40 refining -46 removal -22 removal methods -22
rocker asscmbly -34. 45 spec ifications -23 start· up after overhau l-4 6 sump -34, 44 lappets ;:and pushrods -35 timing covcr -43 timing gears - 38. 43
l orque wrench senings -24 valvcs -46 Engino (3.0 litro) ilO)cill:lr ies • 49. 55 camshalt •. 50. 51. 54 componcnlS e~.-.minlllion lor WC:lr -34. 51 connecting rods -37. 42. 51. 52. 54 cr.-.nkshMt ventoilltion system --53 Crank~hllh -52. 54 Crtlnkshllh pulley -50
c .t1nkshaft rear oil seal -51. 55 cylillde. bores -36. 51 ylinde. hoad s -49. 55 decarbonising -52 descrif)1ion _ 47 dism.-.ntling -29. 49 faull dingnosis -20. 56 lIywhecl/d.ivepl(lte -50. 52 . 55 Iront covc. -50 hOn! plate -54 gudgeon pins -37. 52 IUbricntion system -53 main and big·end bcarings -37, 52 mainten(lnce. routine -48 oil pump -50. 52. 54 operations possible with engine in ca. -48 operations requiring engine .emov,)1 _ 48
piston rings -36. 51 pistons -36. 42. 51, 54 push.ods -35. 51 reassembly -40. 54
refining -56
removal _ 48
removn! methods -48
rocker arms - 49. 51. 55
specifications -25
sump -
50. 55 pppels -35. 50. 51 !lming gears -38. 50. 52. 54 torquo wrcnch sellings -25
.
villvcs -46. 49. 52. 55 Exhaus t syste m remova l and refining -76 EMpnfls ion tank ( coolin g sys tem) removal and refilling -64
F
Facia pilnel t(!mov,)1 and rcfining -188 Fan hub bearing (3.0 lit r e models) .encwal -64
Fan. viscous d rive remov,,1 and refinmg -63 Fnllli (Jingnosis -19 et seq Fault di,)gnosis
lIulOtl1allC lrnnsmrssion -127 tJ,nkmg system -156 Clutch -101 coolmg system -65 clectf1clll system -19. 233 cnlline -20. 56 fuel system cilrbure uor - 85 lucl inlCCho n -85 IHn,hon system -96 mllnu .. 1 !Je.l,hox 122 p.npeller shaft -131 1f!.1f FrOIl! cover (3.0 l i lre engino) reftlovnl 50 FrOllt dir oc tion indicator l c; ,hper
oved'lIul -
145 remov r emoval and retnung -215 F ront log lamp ')nd bu lb
rcmoval ilnd rcfilling -2 I 5 Front suspen sio n COIl sprinU removal and refIning -162 duscnp tlon -158 fault dIagnosis -172 h\,bs-161.162 milintenance. routine -161 stabiliscr bar removal and rcfming -163 Strut removal and refilling -162 lorque wrench sellings - 158 track control arm removal and .elilling -164 Fuel (/lid exhaust systems -66 el $eq Fuel filler cap .cmoval and refining -188 Fuo l injection syste m ')CCclcflltor cable -74. 83
air Cleilller -80 deSCri ption - 77 exhaust manifold - 85 fault diagnosis -85 fuel lank. s&nder unit and filler pipe -83 idle mixture ,)djustment -82
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Page 202 of 205

FORD CAPRI 1974 Workshop Manual inlet manifold - 83
main system components remova l and refilling -80 m~intenilnce, routine -79
specificiltions -67 to rque wrench settings -67 Fuel pump carburettor system cleaning - 68 re mo

inlet manifold - 83
main system components remova l and refilling -80 m~intenilnce, routine -79
specificiltions -67 to rque wrench settings -67 Fuel pump carburettor system cleaning - 68 re moval and refilling - 68
testing -68
fuel inject ion system removal and refining -80 Fuel system (carbureUor) accelera tor cable -74
accelerator shah and pedal - 75 air cleaner - 68
carburetlor -66, 68 to 73
description -67 e~ haust manifold - 76 lault diagnosis -85 luel pump -68 fu el wnk -73, 74 fu el lan k fille r pipe -74 fuel tank sender unit -74 inle l manifold -75 mainte nance, routine -67 specifiCiltions -66 torque wrench senings - 67 Fue l tank cleaning and repai r -74
filler pipe removal and re fi\ling .-74 remova l and refilling -73
sender uni t removal and ref il\in g -74 Fuel tank sender unit (fuel injection models) -83 Fuses
G
general -220 specifica tio ns - 199
Gearbo~ see Manual gearbO K Gudgeon pins - 37. 52
pdbrake adjus tment -153 cable(s} and rod removal and refilling 155 lever removal and refitting -154
warnin g hght switc h -225 Headlights alignment - 212 assembl y: removal and refilling ~ 211 bulbs renewal-2 13 Heater assembly: diSI11(lntting and reassembly 8ehr - 19 4 Smiths standard and heavy duty -196 assembly: removal and ret.tting -193 contlols
adjustmen t -192 removal and refilling ~ 1 93 water valve (heavy dUly heater)
removal and re fitting - 193 History o f tho nlodal-5 Horn faul t tra cing . remova l and refilling -220 Hubs, front
bearings renewal -162 removal. ret lu in g and bearing adjustment -16 1 Iraulic systam (brakes) bleed ing - 152 pipes and hoses removal and refilling -151
Index
Ignition switch and lock -224 Ignition system -87 el seq Ignition sys tem amplrlier module (2 .8 l i\(e mode ls)
r emova l and refilling - 94
condenser (3. 0 litre models) -90 COntact bre aker points (3.0 litre models) - 89
description -88
dis tributo r -
90. 92. 93 fau lt diagnosis -96
firing order -87 mainteMnce. routine -88
spare plugs - 91. 95 speci fications -87
t im ing -94
torque wrench settings -87 In strument cluster ill umina tion switch -224 removal and refitting _ 221 Instrument voltage regulator removal and refilling -226 Interior lamp and bulb
removal and refilling -217
J
Jacking -7
L
lubricants and fluids recommended - 17 lubrication chart - 17 lubrication system
M
2.8 litre engine -39 3.0 litre engi ne -53
Main and big·eOld bO(lrings e~amination and renovation -37, 52 Main bearings (3.0 litro engine) removal - 51 Maintenanco , routine bodywork and fillings d oor ch ec k straps security check - 16 locks, door chec k Straps. tuellilte r C upholstery and carpets - 17 6 windsCtee n illld windows cleilning - 16 braking system
h andbrake linkage lubricat ion -16, 144
h ydraulic fluid levul check /lap up - 16 . 143 hydraulic flu id renewal -16. 144
line s and hoses check -16
pads ilnd shoes we." check -16 , 14 3 servo check -16 . 144 vacuum hose check -16 Clutch adjustment chock -16, 98 cooling syslem
coolan l leve l chec k/top up -16, 59 coolant renewal -16, 59 drivebelt condl tion/wnsion check -16, 59 leaks check - 59 electrical system
ballery elec tro lyt e leve l cheek /top up - 16. 200 equ ipmen t opera tio n check -16. 200 headlamps cleaning -16
253
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Page 203 of 205

$FORD CAPRI 1974 Workshop Manual 2"4 Index ",-----------------------------------------------------------------1 - ligh\s operation check -16 w~she( fluid levels check/lop up - 16, 217, 219 engine crankcase emission valve renewa$

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key fob keyless entry open gas tank gas mileage roof rack sunroof